Magnetic substrates with high magnetic loading

A method of forming a magnetic assembly having at least one magnetic layer having dimensions of thickness, width and length, and at least one printable substrate layer having dimensions of thickness, width and length, the method comprising the steps of:

• a) providing a hot melt magnetic composition at an elevated temperature with an extruder, said magnetic hot melt composition comprising about 75 wt-% to about 95 wt-% of at least one magnetic material and about 5 wt-% to about 25 wt-% of at least one thermoplastic binder;
• b) providing a printable substrate layer selected from paper, paper products and pasteboard;
• c) providing an adhesion promoting layer on said printable substrate layer;
• d) applying said hot melt magnetic composition directly with a slot die head to said printable substrate layer to form a magnetic layer on said printable substrate layer, said magnetic layer having a thickness of about 50 microns to about 305 microns, said adhesion promoting layer between said printable substrate layer and said hot melt magnetic layer;
• and
• e) subjecting said magnetic assembly to a strong magnetic field sufficient to result in a permanent magnetic effectin the assembly.